The present invention relates generally to a prefabricated skylight and curb assembly and methods for installing and fabricating same. More particularly, the invention relates to a skylight and curb assembly incorporating a locking cap having a retainer and a rotatable cover for assisting with installation of roofing membrane, such as thermoplastic polyolefin (TPO), and insulation and providing streamlined installation of the skylight and curb assembly to the roof of a structure.
Skylights are incorporated into buildings, houses, and other structures. They often reduce energy consumption by infusing desirable natural light into the interior of a structure, thereby decreasing dependency on artificial lighting. Water penetration and moisture infiltration into a skylight structure, however, are often concerns with skylights.
Traditionally, skylights are installed by first constructing and securing a roof curb to the roof of a structure at the position where the skylight is to be mounted. A waterproofing membrane, such as TPO, is then affixed to the roof, including being wrapped over and around the roof curb walls, to prevent water penetration. A skylight may then be secured to the roof curb.
In some applications, issues may arise with this multi-step skylight and curb installation process because the skylight curbs are not appropriately shaped and/or sized to securely receive the skylight. Additionally, the installation process may be cumbersome because multiple steps are required at the installation site, and/or the multiple steps may each increase the risk of error during fabrication on-site.
Thus, there is a need for a prefabricated skylight and curb assembly that is simple and easy to install to a roof structure at the installation site while also allowing for effective configuration of waterproofing membrane and insulation to the skylight curb.
The present invention includes a skylight and curb assembly. In one embodiment of the skylight and curb assembly, the assembly may include a roof curb, a skylight, and a locking cap. The roof curb may define an outer perimeter and an inner open perimeter. Further, the roof curb may include a lower end for securing to a roof structure and an upper end for securing the skylight. The locking cap may include a retainer and a cover. The retainer may be disposed outboard of the roof curb between the upper and lower ends. The cover may be adjustably secured to the retainer so that the cover may be moveable between a generally vertical position and a generally horizontal position.
In another embodiment of the skylight and curb assembly, the assembly may include a roof curb, a skylight, and a locking cap having a retainer and a moveable cover. The roof curb may define an outer perimeter and an inner open perimeter. The roof curb may further have a lower end for securing to a roof structure and an upper end for rigidly securing the skylight. The retainer may define a retainer profile having a generally vertically extending member with an upper portion, a lower portion, a curb side, and a cover side. The retainer profile may further include retainer legs disposed on the cover side of the generally vertically extending member of the retainer profile. The cover may define a cover profile having a generally vertically extending member with an upper portion, a lower portion, a retainer side, and an outer side. The cover profile may further include cover legs disposed on the generally vertically extending member of the cover profile. The retainer may be disposed on the outer perimeter of the roof curb between the upper and lower ends of the roof curb. Further, the cover may be adjustably attached to the retainer so that the cover is movable between a generally vertical locked position and a generally horizontal unlocked position.
The skylight and curb assembly of the present invention may further include a barrier for positioning at corners of the roof curb. Further, the assembly may include a corner cap for securing at curb corners between the cover and the skylight. The assembly may also include a gasket for positioning between the roof curb and the cover when the cover is in the generally vertical position. In one embodiment of the skylight and curb assembly of the present invention, the locking cap extends around the entire outer perimeter of the roof curb. For example, the retainer and/or the cover may extend around the entire perimeter of the roof curb.
The present invention also includes a method of fabricating a skylight and curb assembly. In one embodiment, the method includes the step of providing a roof curb defining an outer perimeter and an inner open perimeter. In one embodiment, the roof curb further has a lower end for securing to a roof structure and an upper end. The method may further include the steps of providing a locking cap having a retainer and a cover, rigidly securing the retainer to the outer perimeter of the roof curb between the upper and lower ends, and adjustably securing the cover to the retainer so that the cover is moveable between a generally vertical position and a generally horizontal position relative to the retainer. The method may also include the steps of providing a skylight structure and securing the skylight structure to the upper end of the roof curb.
The present invention also includes a method of installing a skylight and curb assembly to a roof structure. In one embodiment, the method includes the step of providing a skylight and curb assembly having a roof curb, a locking cap, and a skylight. In one embodiment, the roof curb defines an outer perimeter and an inner open perimeter. The roof curb may further have a lower end for securing to a roof structure and an upper end for securing the skylight. The locking cap may include a retainer and a cover. The retainer may be disposed on the outer perimeter of the roof curb between the upper and lower ends. The cover may be adjustably secured to the retainer so that the cover is moveable between a generally vertical position and a generally horizontal position. The method may further include the steps of securing the skylight to the upper end of the roof curb, securing the skylight and curb assembly to a roof structure, positioning the cover in the generally horizontal position, securing roofing membrane to the roof curb; and positioning the cover in the generally vertical position over at least a portion of the roofing membrane after the roofing membrane has been secured to the roof curb.
The present invention relates to a skylight and curb assembly and method of fabricating and installing same. The skylight and curb assembly of the present invention may be prefabricated and fully assembled prior to transporting to an installation site. Additionally, the skylight and curb assembly of the present invention preferably maintains a leak-proof design while still allowing for securing of roofing membrane and/or insulation to the roof curb after the assembly is installed. Thus, the skylight and curb assembly of the present invention preferably allows for a better quality skylight and curb assembly while also allowing for easy and streamlined installation.
The composition, components, materials, sizes, and shapes of the skylight and curb assembly may vary. For example, the design of the assembly may vary depending upon size, shape, and material of the roof structure upon which the assembly is mounted. Additionally, the assembly may vary depending upon the degree of incline of the mounting surface. Although primarily described herein in terms of its use as a prefabricated skylight and curb assembly that provides a better quality and more leak-proof design, it will be clear that the apparatus and method of the present invention may provide additional benefits. Further, the primary components of the skylight and curb assembly as described herein may be combined with additional components and materials without departing from the spirit and the scope of the present invention. The invention will be described with reference to the figures which are an integral non-limiting component of the invention. Throughout the description similar elements will be numbered accordingly.
In the illustrated embodiment of
As shown in
The retainer and cover may be formed of various materials and formed using various methods. In one embodiment, the retainer and/or cover are formed by extrusion techniques. The retainer and cover may be formed of the same or different materials. Preferably the components of the locking cap 40 of the present invention are formed of weather resistant materials. In one embodiment, the retainer and/or cover may be composed of an aluminum alloy such as 6063-T5 aluminum alloy.
As illustrated in
For additional protection against water leakage at the corners, the assembly may further include a corner cap 90 for securing at one or more curb corners on the outer side of the cover 60. In one embodiment, the corner cap 90 is positioned between the cover 60 and the skylight 20. The corner cap 90 may be formed of various materials and formed using various techniques. In one embodiment, the corner cap 90 may be formed using injection molding. In another embodiment, the corner cap 90 may be composed of polymers such as amorphous plastics. For example, the corner cap 90 may be composed of an acrylic-styrene-acrylonitrile (ASA) polymer. Preferably, the corner cap 90 is formed of weather resistant materials.
The assembly may also include a gasket 100, such as a bulb gasket, for positioning between the roof curb and the cover when the cover is in the generally vertical position. The gasket 100 may be formed of various materials and formed using various methods. In one embodiment, the gasket is formed using extrusion techniques. Preferably, the gasket 100 is composed of water resistant materials such as rubbers, elastomers, and/or polymers. In one embodiment, the gasket 100 is formed of a synthetic rubber such as an ethylene propylene diene monomer (EPDM) rubber.
In one embodiment of the skylight and curb assembly 10 of the present invention, such as illustrated in
In one embodiment of the present invention, the outer perimeter 36 of the roof curb 30 may form a generally rectangular shape. Further, the locking cap 40 may include at least four independently movable covers 60 to surround a rectangular roof curb 30 on all four sides. For example, the at least four independently movable covers 60 may form a generally rectangular shape around the roof curb 30 when the at least four independently movable cover are all in the generally vertical position such as shown in
In one embodiment of the present invention as illustrated in
In one embodiment of the present invention as illustrated in
Preferably the design of the skylight and curb assembly of the present invention provides minimal-to-no gaps or spaces for water penetration into the interior of the skylight or roof curb. Thus, the design of the present invention preferably allows for improved waterproofing. Additional components may be incorporated into the assembly of the present invention to provide additional moisture control without departing from the spirit and scope of the present invention.
Because the retainer and cover may be constructed using long extrusions, strengthening and/or compression ribs may be incorporated along the retainers and covers of the present invention without departing from the scope of the present invention. Moreover, additional securing legs, members, and securing elements may be incorporated into the retainers and covers of the present invention without departing from the scope of the present invention. Optional accessories and feature may also be incorporated into the skylight and curb assembly 10 of the present invention without departing from the spirit and scope of the present invention.
The present invention also includes a method of fabricating a skylight and curb assembly. In one embodiment, the method includes the step of fabricating and/or providing a roof curb 30 defining an outer perimeter and an inner open perimeter. In one embodiment, the roof curb further has a lower end for securing to a roof structure and an upper end. The method may further include the steps of providing a locking cap having a retainer 50 and a cover 60. The retainer may be secured to the outer perimeter of the roof curb between the upper and lower ends such as shown in
The method of fabricating a skylight and curb assembly of the present invention may also include the step of providing a barrier 80 and securing the barrier 80 to at least one or more corners of the roof curb. In one embodiment, the barrier is secured prior to securing the retainer. The method of fabricating a skylight and curb assembly of the present invention may also include providing a gasket 100 and/or inserting a gasket between the cover of the locking cap and the roof curb and/or barrier 80, such as shown in
The present invention also includes a method of installing a skylight and curb assembly to a roof structure. In one embodiment, the method includes the step of providing a skylight and curb assembly having a roof curb, a locking cap, and a skylight. In one embodiment, the roof curb defines an outer perimeter and an inner open perimeter. The roof curb may further have a lower end for securing to a roof structure and an upper end for securing the skylight. The locking cap may include a retainer and a cover. The retainer may be disposed on the outer perimeter of the roof curb between the upper and lower ends. The cover may be adjustably secured to the retainer so that the cover is moveable between a generally vertical position and a generally horizontal position. In one embodiment, the locking cap further includes a barrier, gasket, and/or corner cap. The method may further include the steps of securing the skylight and curb assembly to a roof structure, positioning the cover in the generally horizontal position, securing roofing membrane to the roof curb, and positioning the cover in the generally vertical position over at least a portion of the roofing membrane after the roofing membrane has been secured to the roof curb.
In an exemplary method of installing a skylight and curb assembly to a roof structure as illustrated in
The methods of the present invention may include additional steps without departing from the spirit and scope of the present invention. Furthermore, unless otherwise explicitly stated herein, the steps of the method may be performed in various orders.
The skylight and curb assembly of the present invention is particularly suitable for use with many different types and forms of structures, including commercial, industrial, and residential structures. The skylight and curb assembly of the present invention includes a novel locking cap having a movable cover that provides a distinct advantage over traditional skylight and curb designs. Particularly, the design of the present invention allows for installation of roofing membrane and insulation to the roof curb with a fully assembled and constructed skylight and curb. Further, because the skylight and curb assembly of the present invention may be fully constructed and assembled prior to shipment to an installation field site, the design of the skylight and curb assembly of the present invention preferably allows for quick and easy installation at a field site.
While various embodiments and examples of this invention have been described above, these descriptions are given for purposes of illustration and explanation, and not limitation. Variations, changes, modifications, and departures from the apparatuses, systems, and methods disclosed above may be adopted without departure from the spirit and scope of this invention. In fact, after reading the above description, it will be apparent to one skilled in the relevant art(s) how to implement the invention in alternative embodiments. Thus, the present invention should not be limited by any of the above described exemplary embodiments.
Further, the purpose of the Abstract is to enable the various Patent Offices and the public generally, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is not intended to be limiting as to the scope of the invention in any way.
This application is related to and claims priority to U.S. Provisional Patent Application No. 62/399,867 filed Sep. 26, 2016, which is incorporated herein by reference.
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Number | Date | Country |
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19830324 | Jan 2000 | DE |
Entry |
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Translation of DE 19830324 A1. |
Number | Date | Country | |
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20180087278 A1 | Mar 2018 | US |
Number | Date | Country | |
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62399867 | Sep 2016 | US |